The outside door handles are prone to breaking—all doors are affected by this condition.Google+
Car Problem Reports
Chevrolet Astro Outside Door Handles May Break
Chevrolet Astro Problem
Average Mileage: 140,201 mi (13,115 mi - 250,000 mi)
Visitor, 2003 Chevrolet Astro, 175,000 mi
handle broke can open back door
Visitor, 2005 Chevrolet Astro, 100,000 mi
Both door handles broken....have ordered new ones. Seems to me another Government Motors (GM)design flaw..!! Can't wait for Nomobama care to start up...(once we can ACTUALLY sign up for it)...on that gubmnt' web site..!!
Visitor, 1995 Chevrolet Astro, 105,000 mi
I had the same problem with the driver's door. You can buy the replacement handles at the auto parts store. I followed the instructions in my Haynes manual with some success. It took myself longer to than what the instructions stated, and I had to disassemble the lock assembly to put everything back together. This part wasn't apart of the instructions.
Visitor, 1990 Chevrolet Astro, 119,000 mi
Door handles front doors both broke off
Visitor, 2002 Chevrolet Astro
Front power locks quit working
Visitor, 2003 Chevrolet Astro, 96,000 mi
door handle of driver side is broken
Visitor, 1993 Chevrolet Astro, 206,452 mi
Outer door handle broken and rear seal on tranny leaks
Visitor, 2002 Chevrolet Astro, 168,000 mi
door handle broke at the usual spot. I open my door from the inside now.
Visitor, 2002 Chevrolet Astro, 175,000 mi
Driver's door handle broken. Could not install top nut, so I left it off. 20000 miles later the replacement handle is still doing OK.
Visitor, 1996 Chevrolet Astro
240000 miles. Driver handle replaced twice